Mazda Protege 5. Manual - part 96

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–37

01–03A

NO.15 EMISSION COMPLIANCE [ZM]

A3U010318881W57

Diagnostic procedure

15

Emission compliance

DESCRIPTION

•

Emission compliance test failed.

POSSIBLE 

CAUSE

•

Vacuum lines leakage or blockage

•

Cooling system malfunction

•

Spark plug malfunction

•

Leakage from intake manifold

•

Erratic or no signal from CMP sensor

•

Inadequate fuel pressure

•

PCV valve malfunction or incorrect valve installation

•

EGR valve malfunction

•

Exhaust system clogging

•

Fuel tank ventilation system malfunction

•

Charcoal canister damage

•

Excessive carbon is built up in combustion chamber.

•

Improper engine compression

•

Improper valve timing

Warning
The following troubleshooting flowchart contains fuel system diagnosis and repair procedures. 
Read following warnings before performing fuel system services:

••••

Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep 
sparks and flames away from fuel.

••••

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or 
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete 
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this 
manual.
(See 01–14–4 BEFORE REPAIR PROCEDURE.)
(See 01–14–5 AFTER REPAIR PROCEDURE.)

STEP

INSPECTION

ACTION

1

•

Inspect for following:
— Vacuum lines for leakage or blockage
— Electrical connections
— Proper maintenance schedule followed
— Intake-air system and air cleaner element 

concerns: obstructions, leakage or 
dirtiness

•

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

2

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition switch on.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC is displayed:

•

Go to next step.

No

No DTC is displayed:

•

Go to appropriate DTC test.

3

•

Is any other drivability concern present?

Yes

Go to appropriate symptom troubleshooting.

No

Go to next step.

4

•

Connect WDS or equivalent to DLC-2.

•

Access ECT PID.

•

Warm up engine and run it at idle.

•

Verify ECT PID is correct.

•

Is ECT PID correct?

Yes

Go to next step.

No

Inspect for coolant leakage, cooling fan and condenser fan 
operation or thermostat operation.

5

•

Is strong blue spark visible at each 
disconnected high-tension lead while 
cranking engine?

Yes

Inspect for following:

•

Spark plugs malfunction

•

CMP sensor is improperly installed.

•

Damage of trigger wheel on camshaft

•

Open or short circuit on CMP sensor

•

Open or short circuit between CMP sensor and PCM 
terminal 85

Repair or replace malfunctioning parts.

•

If okay, go to next step.

No

Inspect following:

•

High-tension leads

•

Ignition coil and connector

1712-1U-01G(01-03A).fm  37 ページ  ２００１年６月２９日 金曜日 午後４時４５分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–38

End Of Sie

NO.16 HIGH OIL CONSUMPTION/LEAKAGE [ZM]

A3U010318881W58

Diagnostic procedure

End Of Sie

6

•

Install fuel pressure gauge between fuel filter 
and fuel distributor.

•

Start engine and run it at idle.

•

Measure fuel line pressure at idle.

•

Is fuel line pressure correct at idle?

Fuel line pressure
210—250 kPa {2.1—2.6 kgf/cm

2

, 30—36 psi}

Yes

Go to next step.

No

Zero or low:

•

Inspect fuel pump circuit.

•

Inspect for open fuel pump relief valve.

•

Inspect for fuel leakage inside pressure regulator.

•

Inspect for clogged main fuel line.

High:

•

Inspect pressure regulator for high pressure cause.

•

Inspect for clogged fuel return line.

7

•

Remove and shake PCV valve.

•

Does PCV valve rattle?

Yes

Go to next step.

No

Replace PCV valve.

8

•

Inspect for fuel saturation inside charcoal 
canister.

•

Is excess amount of liquid fuel present in 
canister?

Yes

Replace charcoal canister.

No

Inspect fuel tank vent system.
Then, go to next step.

9

•

Is there any restriction in exhaust system?

Yes

Inspect exhaust system.

No

Inspect EGR valve.

10

•

Verify test results.
— If okay, return to diagnostic index to service any additional symptoms.
— If malfunction remains, refer to related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

STEP

INSPECTION

ACTION

16

High oil consumption/leakage

DESCRIPTION

•

Oil consumption is excessive.

POSSIBLE 

CAUSE

•

PCV valve malfunction

•

Improper dipstick

•

Improper engine oil viscosity

•

Engine internal parts malfunction

STEP

INSPECTION

ACTION

1

•

Remove and shake PCV valve.

•

Does PCV valve rattle?

Yes

Go to next step.

No

Replace PCV valve.

2

•

Inspect for following:
— External leakage
— Proper dipstick
— Proper engine oil viscosity

•

Are all items okay?

Yes

Inspect internal engine parts such as valves, valve guides, 
valve stem seals, cylinder head drain passage, piston rings.

No

Service as necessary.
Repeat Step 2.

3

•

Verify test results.
— If okay, return to diagnostic index to service any additional symptoms.
— If malfunction remains, refer to related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

1712-1U-01G(01-03A).fm  38 ページ  ２００１年６月２９日 金曜日 午後４時４５分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–39

01–03A

NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [ZM]

A3U010318881W59

Diagnostic procedure

17

Cooling system concerns — overheating

DETECTION 

CONDITION

•

Engine runs at higher than normal temperature/Overheats.

POSSIBLE 

CAUSE

•

Improper coolant level

•

Blown fuses

•

Coolant leakage

•

Excessive A/C system pressure

•

Improper water/anti-freeze mixture

•

Fans reverse rotation

•

Poor radiator condition

•

Thermostat malfunction

•

Radiator hoses damage

•

Condenser fan is inoperative.

•

Improper or damaged radiator cap

•

Cooling fan is inoperative.

•

Coolant overflow system malfunction

•

Improper tension of drive belt

•

Drive belt damage

STEP

INSPECTION

ACTION

1

•

Inspect following:
— Engine coolant level
— Coolant leakage
— Water and anti-freeze mixture
— Radiator condition
— Collapsed or restricted radiator hoses
— Radiator pressure cap
— Overflow system
— Fan rotational direction
— Fuses

•

Are all items okay?

Yes

Go to next step.

No

Service as necessary.
Repeat Step 1.

2

•

Connect WDS or equivalent to DLC-2.

•

Turn ignition key to ON.

•

Retrieve any DTC.

•

Is “DTC” displayed?

Yes

DTC is displayed:

•

Go to appropriate DTC test.

No

No DTC is displayed:

•

Go to next step.

3

•

Start engine and run it at idle speed.

•

Turn A/C switch on.

•

Does A/C compressor engage?

Yes

Go to next step.

No

Inspect following and repair or replace as necessary:

•

Refrigerant charging amount

•

Open circuit between A/C relay and PCM terminal 96

•

Seized A/C magnetic clutch

•

A/C magnetic clutch malfunction
— If all items are okay, go to inspect following.

•

Refrigerant pressure switch operation

•

Evaporator temperature sensor and A/C amplifier

•

A/C switch is stuck open.

•

Open or short circuit between refrigerant pressure 
switch and PCM terminal 41

•

Open circuit of blower motor fan switch and resistor (if 
blower motor does not operate)

1712-1U-01G(01-03A).fm  39 ページ  ２００１年６月２９日 金曜日 午後４時４５分

SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (ZM)]

01–03A–40

End Of Sie

NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [ZM]

A3U010318881W60

Diagnostic procedure

4

•

Start engine and run it at idle speed.

•

Turn A/C switch on.

•

Do cooling fan and condenser fan operate?

Yes

Go to next step.

No

Cooling fan motor does not operate:

•

Inspect for following:
— Cooling fan relay is stuck open.
— Cooling fan motor malfunction
— Cooling fan motor GND open
— Open circuit between cooling fan motor and relay
— Open circuit between cooling fan relay and PCM 

terminal 47

— Open battery power circuit for cooing fan relay

Condenser fan motor does not operate:

•

Inspect for following:
— Condenser fan relay is stuck open.
— Condenser fan motor malfunction
— Condenser fan motor GND open
— Open circuit between condenser fan motor and relay
— Open circuit between condenser fan relay and PCM 

terminal 45

— Open battery power circuit for condenser fan relay

5

•

Is drive belt okay?

Yes

Go to next step.

No

Replace drive belt.

6

•

Is there any leakage around heater unit in 
passenger compartment?

Yes

Inspect and service heater for leakage.

No

Go to next step.

7

•

Is there any leakage at coolant hoses and/or 
radiator?

Yes

Replace malfunctioning part.

No

Go to next step.

8

•

Cool down the engine.

•

Remove thermostat and inspect operation.
(See 01–12–5 THERMOSTAT REMOVAL/
INSTALLATION.)
(See 01–12–7 THERMOSTAT 
INSPECTION.)

•

Is thermostat okay?

Yes

Engine coolant temperature and thermostat are okay, 
inspect engine block for leakage or blockage.

No

Access ECT PID on WDS or equivalent.
Inspect for both ECT and temperature gauge readings.

•

If temperature gauge on instrument cluster indicates 
normal range but ECT is not same as temperature 
gauge reading, inspect ECT sensor.

•

If temperature gauge on instrument cluster indicates 
overheating but ECT is normal, inspect temperature 
gauge and heat gauge unit.

9

•

Verify test results.
— If okay, return to diagnostic index to service any additional symptoms.
— If malfunction remains, inspect related Service Bulletins and perform repair or diagnosis.

•

If vehicle is repaired, troubleshooting is completed.

•

If vehicle is not repaired or additional diagnostic information is not available, replace PCM.

STEP

INSPECTION

ACTION

18

Cooling system concerns — runs cold

DETECTION 

CONDITION

•

Engine takes excessive period for reaching normal operating temperature.

POSSIBLE 

CAUSE

•

Thermostat malfunction

•

Condenser fan system malfunction

•

Cooling fan system malfunction

STEP

INSPECTION

ACTION

1

•

Is customer complaint “Lack of passenger 
compartment heat” only?

Yes

Inspect A/C and heater system.

No

Go to next step.

2

•

Does engine speed continue at fast idle?

Yes

Go to symptom troubleshooting “NO.9 FAST IDLE/RUNS 
ON [ZM]”.

No

Go to next step.

1712-1U-01G(01-03A).fm  40 ページ  ２００１年６月２９日 金曜日 午後４時４５分